Nirvana Contact Cooled

Overview
Identification and Model Numbers.......................................................................3

General Description.............................................................................................4

Operating Pressures and Environment ...............................................................6

Compressed Air System......................................................................................6

Condensate Removal..........................................................................................7

Coolant /Lubrication System ...............................................................................7

Coolant System—Air Cooled...............................................................................8

Coolant System—Water Cooled .........................................................................8

Intellisys Controller ..............................................................................................8

Short Test ............................................................................................................9

 Nirvana Contact Cooled Compressors
Overview

Nirvana Contact Cooled Training Manual Page 2

IR Global Service Education Team
Issue: 02/USA, February, 2006. Ingersoll-Rand Proprietary Information
 Nirvana Contact Cooled Compressors
Overview

Compressor Model Number Designations

In this section, you will learn about: The diagram below depicts an Ingersoll Rand Nirvana
• How to identify contact cooled Nirvana (IRN) 150 Horsepower, (CC) Contact Cooled
compressors compressor.
• Nirvana rated operating pressures
• What information is provided on compressor
nameplates Designation on USA built Nirvana compressors
• Nirvana cooling system configurations
• Nirvana condensate removal system IRN 150 H - CC
• Nirvana lubrication/coolant system

IR Nirvana Nominal Power HP Contact Cooled

European built units from Unicov Czech Republic,

have a different identification system. The following
diagram depicts an Ingersoll Rand Nirvana (IRN) 110
Kilowatt, (CC) Contact Cooled compressor model
number.

Designation on Unicov built Nirvana compressors

IRN 110 K - CC

Typical Package View

IR Nirvana Nominal Power kW Contact Cooled
Identification
Each Nirvana contact cooled unit worldwide can be
identified by the unique serial number. Look at the
compressor nameplate (shown below) to find the
identification information.

!
Note
Remember
Nominal Power is shown on the Nameplate.

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 Nirvana Contact Cooled Compressors
Overview

50 / 60 Hz NIRVANA CONTACT COOLED 37-75 kW / 50-100 HP Specifications

Lowest pressure Highest Pressure L W H Weight
Nominal kW / HP
4.5 bar / 65 psig 10 bar / 145 psig (mm) (in) (mm) (in) (mm) (in) (kg) (lbs)

1578.6 1352.8 1777.0 1048

37 kW / 50 HP 7.5 M3/min / 264 CFM 5.8 M3/min / 206 CFM
(62.2) (53.3) (70.00) (2310)

45 kW / 60 HP 1578.6 1352.8 1777.0 1048

7.5 M3/min / 264 CFM 6.5 M3/min / 228 CFM
(62.2) (53.3) (70.00) (2310)
55 kW / 75 HP 1800.0 1350.0 1957.0 1531
11.8 M3/min / 418 CFM 8.5 M3/min / 300 CFM
(70.0) (53.2) (77.0) (3374)

1800.0 1350.0 1957.0

75 KW / 100 HP 13.6 M3/min / 480 CFM 11.5 M3/min / 406 CFM 1531 (3374)
(70.0) (53.2) (77.0)

50 / 60 Hz NIRVANA CONTACT COOLED 90-160 kW / 125—200 HP Specifications

Nominal kW / Lowest pressure Highest Pressure L W H Weight
HP 4.5 bar / 145 psig 10.0 bar /145 psig (mm) (in) (mm) (in) (mm) (in) (kg) (lbs)

2556.0 1831.0 2440.00 3650

90 kW / 125 HP 21.1 M3/min / 746 CFM 14.3 M3/min / 506 CFM
(100.0) (72.1) (96.1) (8030)
2556.0 1831.0 2440.00 3650
110 kW / 150 HP 21.1 M3/min / 746 CFM 16.8 M3/min / 595 CFM
(100.0) (72.1) (96.1) (8030)
2556.0 1831.0 2440.00 3650
132 kW / 160 HP 29.0 M3/min / 1023 CFM 21.0 M3/min / 742 CFM
(100.0) (72.1) (96.1) (8030)

2556.0 1831.0 2440.00 3650

160 kW / 200 HP 29.0 M3/min / 1023 CFM 22.8 M3/min / 804 CFM
(100.0) (72.1) (96.1) (8030)

FAD (Free Air Delivery) CFM and M3/min. are full package performance ratings in accordance with CAGI/Pneurop acceptance test standard
PN2CPTC2 or ISO 1217.
**Specification given with air-cooled value. Maximum temperature 46ºC (115ºF)

General Description
Nirvana is a single stage or two stage, (Contact
Cooled) rotary screw compressor. It is driven by a
Hybrid Permanent Magnet (HPM) electric motor,
complete with all relevant associated components.

Nirvana is the first Ingersoll Rand compressor to have

an integral variable speed drive (VSD) within the
package. The variable speed drive and HPM motor
have been performance matched to the requirements
of the compressor and have been optimized to give
the most energy savings possible.

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 Nirvana Contact Cooled Compressors
Overview

The compressor capacity is proportional to the speed A standard Nirvana contact cooled package will have
of the HPM motor, which in turn is controlled by a the following components:
variable speed drive (VSD). The motor speed is
adjusted depending on the target pressure set point • Inlet air filtration
and the system air demand. • Compressor
• Hybrid Permanent Magnet Motor
Customers can configure Intellisys Control Panel • Modular or *Chassis Variable Speed Drive
the unit to run at any • VFD for blower control (on Modular Drives)
pressure from the minimum • Injected coolant lubrication system
of 4.5 bar (65psig) to
• Intellisys Controller (SGN or SGNe)
maximum of 10.0 bar
• Instrumentation
(145psi) by simply
adjusting the pressure • Safety provisions
settings located on the • Oil cooler/Aftercooler
SGN or SGNe Intellisys. • Moisture separator and drain trap
• Acoustic enclosure

*Chassis drive is no longer available.

The motor and airend assembly are isolated from the

base by rubber isolation mounts. Flexible pipe
connections are utilized where necessary to isolate
the main base and customer connections.

T-1 Modular Drive Chassis Drive

Initially, Nirvana compressors were supplied with a

“chassis type” VSD. Later, the chassis drive was
replaced by a “modular type” drive design for
improved serviceability.

The HPM rotor assembly is directly attached to the

male rotor shaft of the airend and shares the same
drive end bearing with the airend. No additional
pulleys or gears are required this improves
mechanical efficiency by reducing the number of
moving /wearing components.

HPM Motor Rotor Isolation mounts are located in three places

1) Air-end Discharge
2) Motor Adapter plate
3) Separator Tank foot

Stator
Airend Male Rotor
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Issue: USA, February, 2006. Ingersoll-Rand Proprietary Information
 Nirvana Contact Cooled Compressors
Overview

Operating Pressures
The normal operating pressure range for Nirvana The air is trapped and compressed by the rotors as it
contact cooled compressors is between 4.5 to 10.3 travels through the airend. Lubricant is injected into
bar (65 psig to 145 psig). the rotor assembly and mixed with the compressed
air. The air-coolant mixture discharged from the
There is a safety valve Safety airend is monitored by temperature sensors for
mounted on the side of Valve protection of the airend.
the Separator Tank and
set for the rated The compressed air, heavily laden with coolant,
pressure of the tank. travels to the separator tank via the tangential entry.
The air-coolant mixture
is directed in a circular
motion around the
inside of the tank. The
37 to 75kW (50 to 100HP) vortex or circular
motion separates a
major portion of the
Operating Environment coolant from the air
Nirvana Contact Cooled compressors are designed for through centrifugal Inlet
a maximum ambient temperature of 46°C (115°F) and force. The vortex action Check
a minimum ambient temperature 1.7°C (35°F). and change of direction Valve
Maximum altitude 1000M (3280 feet). result in a high
Maximum Relative Humidity 95% non-condensing. pre-separation before the air enters the separator
element.
! NOTE Compressed air leaving
the separator element
Nirvana is not suitable for outdoor installation. If contains only 5 parts per
the unit is installed outside and not protected from million (PPM) of Ultra
adverse weather conditions, the factory warranty Coolant. The rest of the
will be void. coolant is collected at the
bottom of the separator Minimum Pressure
and is directed back to Check Valve
the airend through the
integral scavenge line,
Compressed Air System screen, and orifice.
Ambient air enters the package through the intake air
panel. Air is then drawn to the inlet of the air filter The compressed air then
housing. The air filter removes airborne particles and leaves the separator
prevents the entry of the particles into the airend. element passing through
the Minimum Pressure Valve Seat
The inlet air filter condition is monitored by a vacuum Check Valve (MPV)
switch (1-VAC), a normally open switch which closes before entering the
on high inlet vacuum caused by a blocked or clogged aftercooler. The MPV controls sump pressure and
air filter. prevents system pressure from returning to the sump
on shutdown.
The inlet valve opens due to the vacuum that is
created by the rotation of the rotors. The air is drawn The Nirvana aftercooler is cooled by either a water-
through the inlet check valve into the rotor assembly cooled system or an ambient air-cooled system.
for compression. Both systems serve to lower the compressed air
temperature inside the aftercooler, causing the water
vapor present in the compressed air to condense.

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 Nirvana Contact Cooled Compressors
Overview

Condensate Removal System The coolant then travels

A centrifugal moisture separator is located to the anti-condensate
immediately after the aftercooler to collect valve (11-SV). The two-
condensation from the cooled compressed air. position anti-condensate
The droplets of water are forced to the wall of the valve is used to reduce
separator by centrifugal force. Maximum velocity is the coolant flow through
reached near the bottom of the separator where a the compressor,
vortex is formed. The water droplets collect and drain increasing coolant
into the bottom of the separator while the air passes temperature. The
up the vortex and exits the separator increased coolant
temperature reduces Anti– Condensate
The condensate is drained through a valve. Different water vapor condensing Valve 11-SV
valves are used on the various sizes and types of in the coolant.
Nirvana compressors.
The valves on various sized units will be different, see
details in the coolant section of the manual. The
Coolant Lubricant System picture below shows the orifice in two different sized
Nirvana Contact Cooled compressors are factory filled valves.
with SSR Ultra Coolant.

The coolant has three main functions Orifice

• Lubricate bearings and rotors 90 to 160 kW Orifice
• Absorb the heat of compression (125 to 200 HP) 37 to 75 kW
• Sealing between rotors and housings (50 to 100 HP)

The coolant system consists of a sump, cooler,

thermostatic, valve, anti-condensate valve and a
coolant filter. When the unit is operating, coolant is
forced by air pressure from the separator tank to the
thermostatic element inside the thermal valve. The
position of the element (a direct result of coolant
temperature) will determine whether the coolant
circulates through the cooler, bypasses the cooler, or Orifice
mixes the two paths together to maintain an optimum
compressor injection temperature. See photo with From the anti-condensate valve the coolant is injected
directional arrows below for details. into the rotors and bearings of the airend.

“C” Port From Cooler “A” Port The coolant is then discharged from the airend and
To Airend returns to the separator tank via the tangential entry.

“B” Port
From Sump
“D” Port To Cooler
The coolant from the “A” port, returns to the sump
through the full flow coolant filter. The filter is rated at
5 Microns.

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Cooling System (Air cooled)
The aftercooler reduces the discharge air temperature
from the compressor package for down stream
accessories such as dryers or processes. The lower
the package discharge temperature, the easier it is for
dryer(s) to remove moisture from the compressed air.
For optimum dryer performance, the compressed air
discharge temperature should be below 38°C (100°F).
Factors that effect performance of the air cooled
cooling system include:
• Air Flow into the compressor
• Air inlet temperature
• Required CTD (cold temperature difference)
• Ambient air temperature
The ambient air is drawn through the aftercooler by a
large blower and is discharged through the top of the
cabinet.
Aftercooler inlet
Oil Cooler
Aftercooler
Aftercooler Outlet
Oilcooler
Inlet / outlet
Compressed air entering the aftercooler is hot,
moisture saturated air. As the air passes through the
cooler, its temperature will drop, causing the moisture
in the air to condense.
The aftercooler has a centrifugal separator at the
discharge to remove condensed moisture (water) from
the compressed air prior to it exiting the Nirvana.
Water collected from the air in the separator will drain
into the condensate drain and be discharged from the
compressor package to a containment area for
disposal.
Nirvana Contact Cooled Training Manual
IR Global Service Education Team
Issue: USA, February, 2006. Ingersoll-Rand Proprietary Information
Nirvana Contact Cooled Compressors
Overview
Cooling System (Water Cooled)
In a water cooled Nirvana, the aftercooler and oil
cooler are “shell-and-tube” designed heat exchangers.
Both the aftercooler and oil cooler employ “water in
the tube” design.
Cooling water flows in the opposite direction of the oil
or air through each of the two components. A water
solenoid shut off valve is provided in the water
discharge line from the package (4-SV). The tube
bundles are removable for cleaning and servicing.
Cooling Water Piping and Water Quality
Both the water utilized in the system and the water
piping to and from the compressor package must meet
specific criteria. For these details, see the section on
Nirvana Installation and Commissioning.
Intellisys
Controller
The controller
monitors the
preprogrammed
compressor
limits. Should
any limits be
exceeded, the
Intellisys will display a warming or an alarm.
Both “Warnings” and “Alarms” are displayed on the
LCD screen of the Intellisys controller. Warnings will
allow the compressor to continue to run. Alarms will
shut the compressor down.
Major components of the control system include: the
SGN / SGNe controllers, a power supply unit, and a
group of pressure sensors, temperature sensors &
relays to input and receive information from the
Intellisys to support the compressor monitoring
process. This topic is covered in more detail in the
electrical and controls sections.
Power Supply
Board
Page 8
 Nirvana Contact Cooled Compressors
Short Test

Short Test

Answer each question as fully as you can, or pick the best option.
When you finish, check your answers by reading through the section again.

1. What are the maximum operating ambient temperatures for the Nirvana contact
cooled compressors?

2. List three important pieces of information about the compressor that can be
obtained from the compressor model number.

3. What is the horsepower and maximum/minimum operating pressure of an

IRN 125H CC?

4. What are the two types of coolers used on Nirvana? How do they function?

5. What do the following abbreviations stand for?

A. HPM

B. VSD

C. CTD

6. What is the purpose of the condensate removal system?

7. List the three purposes of lubricant in the Nirvana compressor.

Nirvana Contact Cooled Training Manual Page 9

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Issue: 02/USA, February, 2006. Ingersoll-Rand Proprietary Information
 Nirvana Contact Cooled Compressors
Overview

NOTES

Nirvana Contact Cooled Training Manual Page 10

IR Global Service Education Team
Issue: 02/USA, February, 2006. Ingersoll-Rand Proprietary Information